Battery powered compact wire feeder

ABSTRACT

A wire feeder that is powered at least partially by a battery is provided. The wire feeder includes a welding wire spool and a welding wire drive system for receiving welding wire from the spool and feeding the wire through a flexible conduit attached to an enclosure of the wire feeder. A motor of the wire feeder drives the welding wire drive system, powered at least in part by the battery. The wire feeder includes a battery receptacle for receiving the battery. In certain embodiments, the wire feeder may be attached to a body of a user via a harness system.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a Non-Provisional of U.S. Provisional PatentApplication No. 61/467,437, entitled “Battery Power Compact WireFeeder”, filed Mar. 25, 2011, which is herein incorporated by referencein its entirety.

BACKGROUND

This invention relates generally to wire feeders for welding systems.More specifically, this invention relates to a compact, battery poweredwire feeder.

Welding systems generally include an electrode configured to pass an arcbetween a torch and a work piece, thereby heating the work piece tocreate a weld. In many systems, such as metal inert gas (MIG) weldingand stick welding systems, the electrode is a consumable wire that meltsinto the weld to provide a filler material into the weld. In otherwords, a single wire serves both as an electrode and as the fillermaterial. In contrast, other welding systems, such as tungsten inert gas(TIG) welding systems, employ a non-consumable tungsten electrode thatis independent from the filler material. In other words, the TIG weldingprocess does not melt the tungsten electrode into the weld forming onthe work piece. Instead, a user generally holds the TIG torch with thetungsten electrode in one hand, while the user simultaneously andindependently holds the filler material in another hand. The independentfiller material is typically provided in a 36 inch long rod, which ismanually delivered to the work piece, forming a weld that isapproximately twelve inches in length. When the filler rod is almostentirely consumed in the welding process, the operator stops welding,discards the remaining stub of filler material, and begins welding againwith a new filler rod. Unfortunately, this process of starting,stopping, and discarding unused filler material may result in aninefficient use of time and consumables throughout the welding process.In addition, the 36 inch long rods of filler material generally used inthe welding process may offer limited flexibility to the user when thework piece is located in a relatively tight space.

BRIEF DESCRIPTION

In one embodiment, a welding wire feeder includes an enclosure. Theenclosure includes a hub for receiving a welding wire spool and awelding wire drive system for receiving welding wire from the weldingwire spool and feeding the welding wire through a flexible conduitattached to the enclosure. In addition, the enclosure includes a motorfor driving the welding wire drive system and a battery receptacle. Themotor is powered at least in part by a battery, and the batteryreceptacle is for receiving the battery.

In another embodiment, a cordless welding wire feeder system includes ahub for receiving a welding wire spool and a welding wire drive systemfor receiving welding wire from the welding wire spool and feeding thewelding wire through a flexible conduit attached to the enclosure. Inaddition, the enclosure includes a motor for driving the welding wiredrive system and a battery receptacle. The motor is powered at least inpart by a battery, and the battery receptacle is for receiving thebattery. The cordless welding wire feeder system also includes a harnesssystem for attaching the welding wire feeder to a body of a user.

In another embodiment, a method for operating a welding wire feederincludes driving a welding wire drive system using a motor powered atleast in part by a battery disposed in a battery receptacle of anenclosure of the welding wire feeder. The enclosure is configured toattach to a body of a user via a harness system. The method alsoincludes feeding welding wire from a welding wire spool disposed in theenclosure through a flexible conduit attached to the enclosure using thewelding wire drive system.

DRAWINGS

These and other features, aspects, and advantages of the presentinvention will become better understood when the following detaileddescription is read with reference to the accompanying drawings in whichlike characters represent like parts throughout the drawings, wherein:

FIG. 1 is a block diagram of an embodiment of a welding system utilizinga battery powered portable welding wire feeder;

FIG. 2 is a diagrammatical representation of an embodiment of certaincomponents of the wire feeder of FIG. 1;

FIG. 3 is a block diagram of an embodiment of certain components of thewire feeder of FIG. 2, including various control circuitry componentsfor controlling operation of the wire feeder;

FIG. 4 is a perspective view of an embodiment of the wire feeder of FIG.2 attached to the back of a user via a harness system such that weldingwire is conveyed to the left side of the user;

FIG. 5 is a perspective view of an embodiment of the wire feeder of FIG.2 attached to the back of a user via a harness system such that weldingwire is conveyed to the right side of the user;

FIG. 6 is a perspective view of an embodiment of the wire feeder of FIG.2 attached to the back of a user via a harness system such that weldingwire is conveyed upward from the wire feeder;

FIG. 7 is a perspective view of an embodiment of the wire feeder of FIG.2 attached to the front of a user via a harness system such that thewelding wire is conveyed to the right side of the user;

FIG. 8 is a block diagram of an embodiment of the wire feeder of FIG. 2including a shielding gas flow control system for conveying shieldinggas with the welding wire;

FIG. 9 is a block diagram of an embodiment of the wire feeder of FIG. 2showing the removal of certain components from the wire feeder;

FIG. 10 is a perspective view of an embodiment of an attachmentmechanism used to attach a flexible conduit of the wire feeder of FIG. 2to a welding torch of a separate welding system;

FIG. 11 is a diagrammatical representation of the wire feeder of FIG. 2including a return lead extending from an enclosure of the wire feederto a work piece; and

FIG. 12 is a perspective view of an embodiment of the wire feeder ofFIG. 2 attached to an arm of a user via a harness system.

DETAILED DESCRIPTION

Present embodiments are directed to systems and methods for providing aportable welding wire feeder that is powered at least in part by abattery. The wire feeder includes, among other things, a spool forproviding a continuous supply of welding wire, a wire drive system forconveying the welding wire from the spool through a flexible conduitextending from the wire feeder, a motor for powering the wire drivesystem, and a battery receptacle for receiving the battery. The batterymay be removable from an enclosure of the wire feeder, and the batterymay be rechargeable. The wire feeder may also include a harness systemfor attaching the wire feeder to the body of a user, allowing the userto move around while welding using the continuous wire feed from thewire feeder. The harness system and battery operation may increaseportability of the wire feeder, allowing greater flexibility for theuser.

Turning now to the figures, FIG. 1 illustrates a tungsten inert gas(TIG) welding system 10 including a power supply 12, a shielding gassource 14, a cooling system 16, a wire feeder 18, and a welding torch20. In the illustrated embodiment, the power supply 12 provides power tothe welding torch 20 via a supply conduit 22. The power supply 12 maysupply a direct current (DC) or alternating current (AC) to the weldingtorch 20 depending on the desired application. For example, an ACcurrent may be suited for welding aluminum or magnesium, and a DCcurrent may be suited for welding stainless steels, nickel, or titanium.In addition to matching the current to the material selection, theoutput of the power supply 12 may be varied to obtain desired weldcharacteristics. For example, a low AC frequency (e.g., 60 Hz) currentmay generate a wide arc with shallow penetration of a work piece 24,while a high AC frequency (e.g., 200 Hz) current may generate a focusedarc with deeper penetration into the work piece 24.

In addition to the frequency of the current, the power supply 12 mayvary the amperage of the current output to the welding torch 20. Thesetting for the amperage output by the power supply 12 may be adjustedby setting a knob or button on the power supply 12, or may be set by aremote control 26. For example, a welding system 10 may include a footpedal remote control 26 that allows the operator to make currentadjustments during welding by either holding down the foot pedal orfeathering the foot pedal remote control 26 to vary the amperage. Theremote control 26 may also include a finger tip trigger control, audiblecommand, or other form of input to signal the power supply 12 to outputa corresponding current.

In addition, the welding torch 20 may be supplied with a shielding gasfrom the shielding gas source 14. In general, the shielding gas may besupplied to the welding torch 20 and expelled from the welding torch 20at the location of the weld. The shielding gas may be expelledimmediately prior to striking the welding arc, throughout welding,and/or until shortly after the welding arc is extinguished. Theshielding gas protects the welding area from atmospheric gases such asnitrogen and oxygen, which can cause fusion defects, porosity, and weldmetal embrittlement. The shielding gas may also transfer heat from thewelding electrode to the metal and may help to start and maintain astable arc.

The shielding gas may be provided in a cylindrical container anddelivered to the welding torch 20 via a conduit 28, a gas valve 30, anda supply conduit 32. A regulator on the gas source 14 may allow anoperator to limit the pressure of the gas delivered to the gas valve 30to obtain a desired flow rate. Further, the gas valve 30 may provide forstopping and starting the flow of the shielding gas to the welding torch20 in coordination with other welding operations.

The welding system 10 may be provided with a cooling system 16 to reduceheat build-up in the welding torch 20. The cooling system 16 may takevarious forms including gas cooled and liquid cooled systems. Thecooling system 16 may provide for circulation of the coolant via acoolant supply conduit 34, the supply conduit 22, and a coolant returnconduit 36. The cooling system 16 may be powered from the power supply12 via a coolant system power cord 38.

In general, the welding system 10 may provide for current flow via awork piece 24 to the power supply 12. For example, as depicted in FIG.1, the welding system 10 may include a cable 40 that is secured to thework piece 24 via a work clamp 42. In this configuration, the currentprovided by the power supply 12 flows through the supply conduit 22 tothe welding torch 20, flows across an arc from an electrode 44 to thework piece 24, and returns to the power supply 12 via the work clamp 42and the cable 40.

The welding system 10 includes a wire feeder 18 that is powered at leastpartially by a battery, making the wire feeder 18 relatively portable.The wire feeder 18 may provide a continuous feed of welding wire 46 foruse during the welding operation. This welding wire 46 is deliveredtoward the work piece 24 and deposited into the weld forming on the workpiece 24 after being heated by the welding arc. Continuously fed weldingwire 46 may offer an improvement to typically used filler material rods,as described above, that are fed manually to the weld, as the continuousfeed reduces an amount of wasted filler material (e.g., a stub at theend of a filler rod) and an amount of time spent discarding andreplacing the filler rod. In addition, the wire feeder 18, which isportable and capable of being decoupled from other components of thewelding system 10, may offer an unprecedented degree of flexibility forthe welding operator.

Although the wire feeder 18 is at least partly battery powered, a powerconnection 48 may extend from the wire feeder 18 to receive additionalpower from the power supply 12, or another outside power source. Incertain embodiments, power received by the wire feeder 18 through thepower connection 48 may be used to recharge a battery within the batterypowered wire feeder system 18, or to supply a portion of the power usedto operate the wire feeder 18. In certain embodiments, other connectionsmay couple the wire feeder 18 with the power supply 12 or othercomponents of the welding system 10 for communicating signals to controla wire feed speed for the wire feeder 18. As previously mentioned, thewire feeder 18 is at least partially battery operated. Because the wirefeeder 18 is entirely battery operated, it may provide a portable,compact, and cordless system for feeding wire continuously to a weldsite.

It should be noted that the welding system 10 illustrated in FIG. 1 isspecific to tungsten inert gas (TIG) welding applications. However, theportable wire feeder 18, described in detail below, may be used in avariety of other welding contexts including, but not limited to, gaswelding (e.g., oxyacetylene gas welding) and plasma welding. Similar toTIG welding, these welding applications generally involve a usermanually feeding a filler material rod to the weld location with onehand while positioning the welding torch 20 with the other hand. Indeed,any welding application that typically employs consumable rods fordepositing filler material into the weld may benefit from the wirefeeder 18 described herein.

FIG. 2 is a diagrammatical representation of an embodiment of certaincomponents of the wire feeder 18 of FIG. 1. In the illustratedembodiment, the wire feeder 18 includes, among other things, anenclosure 60, a welding wire spool 62, a welding wire drive system 64, amotor 66, and a battery 68. The enclosure 60 may include a spool mount(e.g., a hub) 72 configured to receive the spool 62, wire drive 64,motor 66, and a battery receptacle 70 configured to receive the battery68. Indeed, the battery 68, which may be a rechargeable battery, may beremoved from the battery receptacle 70 of the enclosure 60 whenrecharging or replacement of the battery 68 is desired. Similarly, thespool 62 may also be removed from the enclosure 60 and replaced when thewelding wire 46 of the spool 62 has been consumed. The spool 62, wiredrive 64, motor 66, and battery 68 facilitate the continuous feeding ofwelding wire 46 through a flexible conduit 78 extending from theenclosure 60. An operator may grasp the flexible conduit 78 at an enddistal to the enclosure 60 in order to manipulate the welding wire 46toward the arc formed between the electrode 44 and the work piece 24.

The welding wire 46 is supplied by the welding wire spool 62, which maybe mounted on the spool mount 72 within the enclosure 60. It may bedesirable for the size, weight, and type of welding wire 46 on the spool62 to conform to an industry standard. For example, the spool 62 mayhave a diameter of approximately four inches in order to maintain aweight of the wire feeder 18 that is light enough to be portable. Suchwelding wire spools 62 generally weigh approximately one pound foraluminum welding wire or approximately two pounds for steel, stainlesssteel, or nickel welding wire 46. The wire feeder 18 described hereinmay accommodate spools 62 of larger standard sizes as well, or mayaccommodate a custom sized spool 62 designed specifically for the wirefeeder 18.

The illustrated welding wire drive system 64 includes a pair of feedwheels 74 and 76 that are configured to feed the welding wire 46 fromthe spool 62 through the flexible conduit 78 attached to the enclosure60. The first feed wheel 74 may be an idler wheel configured to rotaterelative to the enclosure 60 as the welding wire 46 moves, while thesecond feed wheel 76 may be a drive wheel configured to be turned by themotor 66 in order to urge the welding wire 46 toward the flexibleconduit 78. In accordance with other embodiments of the wire feeder 18,the welding wire drive system 64 may include two or more pairs of feedwheels driven by the motor 66 in order to feed the welding wire 46.

The motor 66 may include, among other things, a motor drive 80 andcontrol circuitry 82 for controlling operation of the motor drive 80, asdiscussed in detail below. The motor 66 is powered at least in part bythe battery 68 located in the battery receptacle 70 of the enclosure 60.In certain embodiments, the motor 66 may receive supplemental power fromthe power supply 12 of the welding system 10, or any other externalpower supply, via the optional power connection 48. Indeed, the powerconnection 48 may receive power from the external power source (e.g.,power supply 12) for recharging the battery 68 or providing additionalpower to drive the motor 66. Other embodiments may include a quickrecharge feature for use when the battery 68 is rechargeable. Such afeature may include charging circuitry in communication with the powerconnection 48 to facilitate recharging of the battery 68 while thebattery 68 is in the enclosure 60 of the wire feeder 18. In theillustrated embodiment, the enclosure 60 does not include the powerconnection 48, making the wire feeder system 18 entirely batteryoperated and cordless. This may increase the portability and flexibilityof operation of the wire feeder 18.

FIG. 3 is a block diagram of an embodiment of certain components of thewire feeder 18, including various components of the control circuitry 82for controlling operation of the wire feeder 18. As illustrated, thecontrol circuitry 82 may include a motor drive circuit 94, a processor96, a memory 98, interface circuitry 100, and operator interfacecircuitry 102. These components of the control circuitry 82 may belocated within the motor 66, as shown in FIG. 2, or in one or moredifferent locations within the enclosure 60 of the wire feeder 18.Certain circuitry components may communicate with components of thewelding system 10 located generally outside the enclosure 60 in order tocontrol a wire feed speed of the welding wire 46 exiting the wire feeder18 toward the welding application.

The motor drive circuit 94 communicates with the processor 96 in orderto operate the motor drive 80 at an appropriate speed for feeding thewelding wire 46 supplied by the spool 62 through the flexible conduit78. The processor 96 may determine the appropriate speed based onsignals from the interface circuitry 100 and operator interfacecircuitry 102. In addition, the processor 96 may be operably coupled tothe memory 98 in order to execute instructions for determining theappropriate wire feed speed based on these signals.

The interface circuitry 100 may communicate power supplied by thebattery 68 to the processor 96 to power operations of both the processor96 and the motor drive 80. The interface circuitry 100 also may conveyadditional power from certain components of the welding system 10 (e.g.,the power supply 12 via the power connection 48) for operating the motordrive 80. Further, the interface circuitry 100 may transmit signalsrelated to various operating parameters of the welding system 10 (e.g.,current output of the power supply 12) in order to control wire feedspeed. For example, when the power supply 12 provides or adjusts acurrent to the welding torch 20, a corresponding signal may becommunicated to the processor 96 via the interface circuitry 100.Accordingly, a signal may be sent from the processor 96 to the motordrive circuit 94 for turning on or adjusting the speed of the motordrive 80. Signals from components of the welding system 10 that areseparate from the wire feeder 18 may be communicated wirelessly orthrough a cable that plugs into the welding system 10 to activate thewelding wire drive system 64. Wireless communication between the weldingsystem 10 and the wire feeder 18 may allow a certain ease ofmanipulation of the wire feeder 18 relative to other welding systemcomponents, further increasing portability of the wire feeder 18.

The operator interface circuitry 102 may include user input devices ofthe wire feeder 18 for manually adjusting the wire feed speed. Forexample, the operator interface circuitry 102 may be linked to a controlpanel located on an outer surface of the enclosure 60. In otherembodiments, the operator interface circuitry 102 may communicatesignals from a trigger 104 positioned along the flexible conduit 78.Indeed, an operator may manipulate the welding torch 20 in one hand andthe flexible conduit 78 for conveying the welding wire 46 in the otherhand, activating the welding wire drive system 64 of the wire feeder 18based on depression of the trigger 104 while continuously welding.

FIG. 4 is a perspective view of an embodiment of the wire feeder 18 ofFIG. 2 having the enclosure 60 attached to a torso 116 of a user 118 viaa harness system 120 such that welding wire 46 is conveyed to the leftside of the user 118. The harness system 120 of the wire feeder 18 maybe used for attaching the enclosure 60 to a body of the user 118, whichmay include, among other things, the torso 116. In the illustratedembodiment, the harness system 120 includes straps through which thearms of the user 118 may be inserted. In this way, the portable wirefeeder 18 may be worn as a backpack, secured to the back of the user'storso 116 so that the user 118 may maneuver the welding torch 20 in aright hand 122 and the flexible conduit 78 in a left hand 124. Thepreviously discussed trigger 104 may be located along an end portion ofthe flexible conduit 78 such that the user 118 may control the speed ofthe welding wire 46 exiting the wire feeder 18 during a welding process.Since the wire feeder 18 is powered by the battery 68 and worn aroundthe torso 116 of the user 118, the user 118 may manipulate both thewelding torch 20 and the welding wire 46 exiting the flexible conduit 78with relatively greater ease than possible using a larger bench-stylewire feeder.

It should be noted that other arrangements of components within theenclosure 60 of the wire feeder 18 may be possible, and otherarrangements of the harness system 120 may be used to secure theenclosure 60 to the torso 116 of the user 118. Certain arrangements ofthe wire feeder 18 may be worn on the front or the back of the user 118,and some embodiments allow the user 118 to manipulate the welding wire46 using either the right hand 122 or the left hand 124. For example,FIG. 5 shows the enclosure 60 attached to the user's back in order toconvey the welding wire 46 through the flexible conduit 78 to the righthand 122 of the user 118. This arrangement may be especially useful fora left-handed user 118. Indeed, the wire feeder 18 of FIG. 5 may be thewire feeder 18 of FIG. 4 rotated 180 degrees. In other words, the wirefeeder 18 and associated harness 120 may be easily reversible in certainembodiments. For example, the harness system 120 may be removed from theuser 118, the entire wire feeder 18 turned 180 degrees, and the harnesssystem 120 replaced on the user 118 to switch between these differentarrangements.

FIG. 6 is a perspective view of an embodiment of the wire feeder 18 ofFIG. 2 attached to the back of the user 118 via the harness system 120such that welding wire 46 is conveyed upward from the enclosure 60through the flexible conduit 78. This configuration of the harnesssystem 120 relative to the enclosure 60 and components internal to theenclosure 60 may allow the user 118 to manipulate the flexible conduit78 using the right hand 122 or the left hand 124 without removing theenclosure 60 from the user's torso 116. It should be noted that thebattery 68, the motor 66, the welding wire drive system 64, and thespool 62 may be arranged in the enclosure 60 in any suitableconfiguration for directing the welding wire 46 from the enclosure 60through the flexible conduit 78 in an upward direction.

FIG. 7 illustrates the wire feeder 18 having the enclosure 60 attachedto a front side of the user's torso 116. The wire feeder 18 in theillustrated embodiment may be the same wire feeder as shown in either orboth of FIGS. 4 and 5, attached via the harness system 120 to the user'sfront instead of the user's back. This may allow the user 118 tomanipulate the welding wire 46 with the right hand 122 while maintainingthe orientation of internal components of the wire feeder 18 as shown inFIG. 4.

FIG. 8 is a block diagram of an embodiment of the wire feeder 18including a shielding gas flow control system 136 for conveyingshielding gas 138 through the flexible conduit 78 along with the weldingwire 46. This may be useful for routing the shielding gas 138 throughthe flexible conduit 78 to shield the welding wire 46 from contaminantsas the welding wire 46 is melted onto the work piece 24. This shieldinggas flow control system 136 may provide the shielding gas 138 to theweld in addition to or in lieu of shielding gas supplied through thewelding torch 20. In the illustrated embodiment, the enclosure 60includes a gas cylinder receptacle 140 for receiving a shielding gascylinder 142, and the shielding gas flow control system 136 is designedto receive the shielding gas 138 from the shielding gas cylinder 142when the shielding gas cylinder 142 is inserted into the shielding gascylinder receptacle 140. In certain embodiments, the shielding gas flowcontrol system 136 may control the amount of shielding gas 138 deliveredthrough the flexible conduit 78 (e.g., using flow control valves) basedon the speed of the motor drive 80, as determined by the controlcircuitry 82 of the wire feeder 18. The shielding gas cylinder 142 maybe removed from the shielding gas cylinder receptacle 140 and replacedwith another shielding gas cylinder 142 when the shielding gas 138 isdepleted. The shielding gas 138 may be a similar or different inert gas(e.g., argon) than the shielding gas provided to the welding torch 20 bythe gas source 14. Furthermore, the shielding gas flow control system136 may receive the shielding gas 138 from the gas source 14 in order todeliver the shielding gas 138 through the flexible conduit 78.

FIG. 9 is a block diagram of an embodiment of the wire feeder 18 showingthe removal of certain components from the enclosure 60. It may bedesirable to remove such components as the welding wire spool 62 and/orthe battery 68 from the enclosure 60 of the portable wire feeder 18. Asthe welding wire drive system 64 conveys the welding wire 46 from thespool 62 through the flexible conduit 78, the spool 62 may eventuallyempty of the welding wire 46. At this point, a new welding wire spool 62may be inserted into the enclosure 60 to supply the welding wire 46. Toaccommodate this, a spool receptacle 150 may be located in the enclosure60 to allow for insertion and/or removal of the spool 62.

Likewise, it may be desirable for the battery 68 to be removed from theenclosure 60 for battery replacement or recharging (if the battery 68 isrechargeable). The illustrated embodiment shows both the battery 68 andthe spool 62 being removed from their respective receptacles 70 and 150.Arrows 152 and 154 indicate downward directions in which the battery 68and the spool 62, respectively, may be lowered from the enclosure 60.The enclosure 60 may include one or more covers that are hinged orremovable to facilitate removal of the battery 68, the spool 62, andother components (e.g., the shielding gas cylinder 142 if present) fromthe enclosure 60. In certain embodiments, such covers may each feature aquick release mechanism, such as a snap fit feature, to allow the user118 or someone else to easily open the cover(s) to remove the spool 62and/or the battery 68. It should be noted that the enclosure 60 may bearranged to allow removal of these internal components in otherdirections; however, removal through the bottom of the enclosure 60 mayenable the user 118 to remain wearing the wire feeder 18 on the user'storso 116 while someone else replaces the component(s). In addition, theprocess of removing the spool 62 from the enclosure 60 may includeadditional steps such as removing the spool 62 from the spool mount 72upon which the spool 62 is situated during wire feeder operation.

FIG. 10 is a perspective view of an embodiment of an attachmentmechanism 166 used to attach the flexible conduit 78 of the wire feeder18 to the welding torch 20. The attachment mechanism 166 may be part ofthe flexible conduit 78, an integral component of the welding torch 20,or a separate component that may be selectively attached to both theflexible conduit 78 and the welding torch 20. In the illustratedembodiment, the welding torch 20 includes a torch handle 168, a torchnozzle 170, and a back cap 172. The illustrated attachment mechanism 166is attached to the welding torch 20 near the handle 168, between thenozzle 170 and back cap 172, but in other embodiments, the attachmentmechanism 166 may attach at different points along the welding torch 20.

In some embodiments, the attachment mechanism 166 may include a quickrelease feature that allows the flexible conduit 78 to be easily engagedor disengaged with the welding torch 20 when desired. During weldingoperations, an operator may desire to reorient the welding torch 20relative to the work piece 24 in order to access the weld site. Toaccommodate this reorientation of the welding torch 20, it may bedesirable for the attachment mechanism 166 to allow a correspondingadjustment of the orientation of the flexible conduit 78 relative to thewelding torch 20. For example, the attachment mechanism 166 may rotaterelative to an axis 174 of the welding torch 20 as it attaches theflexible conduit 78 to the welding torch 20. This would allow an angle176 between the flexible conduit 78 and the welding torch 20 to beadjusted so that the flexible conduit 78 remains attached to the weldingtorch 20 throughout the welding process, even as the welding torch 20 isrepositioned relative to the work piece 24.

FIG. 11 is a diagrammatical representation of the wire feeder 18 feedingthe welding wire 46 through the flexible conduit 78 in a hot wire mode.That is, the wire feeder 18 supplies a charge carrying welding wire 46to the work piece 24. The current flowing through the welding wire 46heats the wire to a relatively higher temperature than possible withoutthe current, allowing the welding wire 46 to be deposited more quicklyon the work piece 24 to make the welding process more time efficient. Inorder to facilitate the current flowing through the welding wire 46, thewire feeder 18 may include a return lead 186 extending from theenclosure 60 to the work piece 24 via a cable 188. The wire feeder 18may include a relatively small power source connected to both thewelding wire 46 and the return cable 188. This power source may be thesame battery 68 used to power the motor 66 for feeding the welding wire46, or a separate power source. As the welding wire 46 is brought intocontact with the work piece 24, a loop closes between the cable 188,work piece 24, welding wire 46, and power source, allowing the currentto flow through and heat the welding wire 46. Thus, the wire feeder 18may support hot wire welding or cold wire welding.

It should be noted that the return lead 186 may be a clamp similar tothe work clamp 42 of FIG. 1, extending from the enclosure 60 via thecable 188 and fixed to the work piece 24 throughout the weldingoperation. In other embodiments, however, the return lead 186 extendingfrom the enclosure 60 may be selectively brought into contact with thework piece 24 during welding. For example, the return lead 186 may beattached to a glove worn by the user 118 in order to allow the user 118greater flexibility in positioning a point of contact between the returnlead 186 and the work piece 24.

FIG. 12 is a perspective view of an embodiment of the wire feeder 18 ofFIG. 2 attached to an arm 190 of the user 118 via the harness system120. As previously mentioned, the harness system 120 may be used forattaching the enclosure 60 of the wire feeder 18 to a body, which mayinclude the torso 116, the arm 190, or other body parts of the user 118.Attaching the wire feeder 18 to the arm 190 may be beneficial forsupplying a continuous feed of the welding wire 46 toward the hand(e.g., the right hand 122) of the arm 190 due to the close proximity ofthe enclosure 60 to the right hand 122. As a result, the wire feeder 18may provide a continuous feed of the welding wire 46 for use in awelding operation, while enabling the user 118 to manipulate the weldingwire 24 and other welding equipment with an unprecedented degree offlexibility.

While only certain features of the invention have been illustrated anddescribed herein, many modifications and changes will occur to thoseskilled in the art. It is, therefore, to be understood that the appendedclaims are intended to cover all such modifications and changes as fallwithin the true spirit of the invention.

1. A welding wire feeder, comprising: an enclosure, wherein theenclosure comprises: a hub for receiving a welding wire spool; a weldingwire drive system for receiving welding wire from the welding wire spooland feeding the welding wire through a flexible conduit attached to theenclosure; a motor for driving the welding wire drive system, whereinthe motor is powered at least in part by a battery; and a batteryreceptacle for receiving the battery.
 2. The welding wire feeder ofclaim 1, comprising a harness system for attaching the enclosure to abody of a user.
 3. The welding wire feeder of claim 1, wherein thewelding wire drive system is activated based on depression of a trigger.4. The welding wire feeder of claim 1, wherein the welding wire drivesystem is activated based on a signal received from a separate weldingsystem.
 5. The welding wire feeder of claim 4, wherein the signal isreceived from the welding system wirelessly.
 6. The welding wire feederof claim 1, wherein the enclosure comprises a power connection forreceiving power from an external power source.
 7. The welding wirefeeder of claim 1, wherein the enclosure comprises a shielding gas flowcontrol system for receiving shielding gas and delivering the shieldinggas through the flexible conduit.
 8. The welding wire feeder of claim 7,wherein the enclosure comprises a shielding gas cylinder receptacle forreceiving a shielding gas cylinder, wherein the shielding gas flowcontrol system receives the shielding gas from the shielding gascylinder when the shielding gas cylinder is inserted into the shieldinggas cylinder receptacle.
 9. The welding wire feeder of claim 1,comprising an attachment mechanism for attaching the flexible conduit toa welding torch of a separate welding system.
 10. The welding wirefeeder of claim 1, wherein the welding wire spool is removable from theenclosure and replaceable.
 11. The welding wire feeder of claim 1,comprising a return lead extending from the enclosure, wherein thereturn lead permits an electrical current to flow from the batterythrough the welding wire and back to the battery through the returnlead.
 12. A cordless welding wire feeder system comprising: a weldingwire feeder, comprising: a hub for receiving a welding wire spool; awelding wire drive system for receiving welding wire from the weldingwire spool and feeding the welding wire through a flexible conduitattached to the enclosure; a motor for driving the welding wire drivesystem, wherein the motor is powered at least in part by a battery; anda battery receptacle for receiving the battery; a harness system forattaching the welding wire feeder to a body of a user.
 13. The cordlesswelding wire feeder system of claim 12, wherein the welding wire drivesystem is activated based on depression of a trigger.
 14. The cordlesswelding wire feeder system of claim 12, wherein the welding wire drivesystem is activated based on a signal received from a separate weldingsystem.
 15. The cordless welding wire feeder system of claim 14, whereinthe signal is received from the welding system wirelessly.
 16. Thecordless welding wire feeder system of claim 12, wherein the weldingwire feeder comprises a shielding gas flow control system for receivingshielding gas and delivering the shielding gas through the flexibleconduit.
 17. The cordless welding wire feeder system of claim 12,wherein the welding wire feeder comprises a shielding gas cylinderreceptacle for receiving a shielding gas cylinder, wherein the shieldinggas flow control system receives the shielding gas from the shieldinggas cylinder when the shielding gas cylinder is inserted into theshielding gas cylinder receptacle.
 18. The cordless welding wire feedersystem of claim 12, comprising an attachment mechanism for attaching theflexible conduit to a welding torch of a separate welding system. 19.The cordless welding wire feeder system of claim 12, comprising a returnlead extending from the welding wire feeder, wherein the return leadpermits an electrical current to flow from the battery through thewelding wire and back to the battery through the return lead.
 20. Amethod for operating a welding wire feeder, comprising: driving awelding wire drive system with a motor powered at least in part by abattery disposed in a battery receptacle of an enclosure of the weldingwire feeder, wherein the enclosure is configured to attach to a body ofa user via a harness system; and feeding welding wire received from awelding wire spool disposed in the enclosure through a flexible conduitattached to the enclosure with the welding wire drive system.